US7195156B2 - Pick-to-light system for replenishing manufacturing kits - Google Patents
Pick-to-light system for replenishing manufacturing kits Download PDFInfo
- Publication number
- US7195156B2 US7195156B2 US11/347,684 US34768406A US7195156B2 US 7195156 B2 US7195156 B2 US 7195156B2 US 34768406 A US34768406 A US 34768406A US 7195156 B2 US7195156 B2 US 7195156B2
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- US
- United States
- Prior art keywords
- manufacturing kit
- parts
- manufacturing
- display
- kit
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
- G06Q10/087—Inventory or stock management, e.g. order filling, procurement or balancing against orders
Definitions
- the present invention relates to an inventory management system, and more specifically, to a system and method for replenishing manufacturing kits using a pick-to-light system.
- the inventory management system reduces labor costs and decreases the inaccuracies of manual kit replenishment systems.
- the present replenishing system provides a shelving system electronically divisible into racks, each rack having vertical and horizontal channels containing shelf communication circuitry. Within each rack there are a plurality of storage bins containing the parts needed for replenishing the manufacturing kits. Each storage bin and manufacturing kit are identified by barcodes and read into the system with scanners.
- a rack control unit located proximate each rack includes a rack processor in communication with other rack processors via a communications bus linking racks within the shelving system. It also controls shelf electronics embedded within the vertical and horizontal channels of each rack and indirectly communicates to a pick station processor located on a mobile pick station through a network node proxy.
- the mobile pick station includes a touchscreen display, a barcode scanner, a pick-station processor and a network interface.
- the pick-station processor communicates with a remote data server that provides specification data for each manufacturing kit. From the specification data, a map of the manufacturing kit is generated and displayed onto the touchscreen display. This map guides the user through a kit replenishment process.
- system of the present invention can also be used to replenish the parts in the storage bins.
- FIG. 1 is a schematic illustration of a pick-to-light system of the present invention.
- FIG. 2 is an illustration of a rack system for the pick-to-light system according to the present invention.
- FIGS. 3 a and 3 b depict a flow diagram for a pick-to-light method according to the invention.
- FIG. 4 is a screen shot of a touch screen interface for the pick-to-light system of the present invention.
- FIG. 5 depicts a flow diagram for servicing emergent requirement with a pick-to-light method according to the inventor.
- FIG. 1 illustrates an inventory management system for replenishing manufacturing kits using a pick-to-light system 10 that generally includes a shelving system 12 , a network node proxy 50 , a mobile pick-to-light cart 100 , and a data server 120 .
- Shelving system 12 is electrically divisible into racks 36 a , 36 b . . . 36 n each having individual rack control units 20 a , 20 b . . . 20 n .
- Multiple columns of racks 36 a , 36 b . . . 36 n , each having shelves 24 a , 24 b . . . 24 n are shown. More or fewer racks of shelves may be included, but seven shelves per rack is typical.
- the rack structure of shelving system 12 is constructed with vertical and horizontal channels 40 , 42 that house system communication circuitry 44 including shelf electronics and rack communication circuitry.
- Rack control units located proximate to each rack 36 a , 36 b . . . 36 n include rack processors 47 a , 47 b . . . 47 n .
- Peer-to-peer communication between racks 36 a , 36 b . . . 36 n is accomplished via a node communications bus 49 connected to each rack processor 47 a , 47 b . . . 47 n within rack control units 20 a , 20 b . . . 20 n.
- Each shelf 24 a , 24 b . . . 24 n holds several storage bins 26 . Depending upon the system design, the number of shelves 24 a , 24 b . . . 24 n and storage bins 26 may vary, but seven or eight storage bins 26 per shelf 24 a , 24 b . . . 24 n is typical.
- Each storage bin 26 has a label designation referred to as a pick-face 28 that includes a barcode 29 identifying, for example, the part number, type and quantity of each part.
- Located below each pick-face 28 is a group of indicator lights or pick-lights, generally one red 30 , one yellow 32 and one green 34 .
- Pick-lights 30 , 32 , 34 can be assigned for different purposes including, but not limited to, one light used for a person replenishing kits, a second for a person assembling a different kit that may use some of the same parts, and a third for a person restocking the kit bins.
- Network node proxy 50 includes a node processor 52 communicating with rack control units 20 a , 20 b . . . 20 n via node communications bus 49 .
- network node proxy 50 receives and processes commands from mobile pick station 100 via an Ethernet or other communication platform through network interface 58 .
- network interface 58 is a wireless network interface.
- Mobile pick station 100 includes a pick station processor 102 in communication with a barcode scanner 106 , a touchscreen display 108 , and a network interface 110 .
- Network interface 110 communicates with data server 120 and network node proxy 50 .
- such communication is wireless.
- the examples used herein are applicable to one mobile pick station 100 , however, multiple pick stations 100 can be used simultaneously for different tasks.
- Data server 120 includes databases, images, and programs needed to operate the pick-to-light system 10 .
- data server 120 includes a web server 121 for processing web-related applications.
- the communication between mobile pick station 100 and data server 120 is via communications interface 122 and is preferably wireless. Other equivalent communication platforms may also be used.
- the pick-to-light system 10 is capable of replenishing one or more manufacturing kits 132 simultaneously using a barcode 130 to track each manufacturing kit 132 .
- Barcode 130 affixes to the outside of each manufacturing kit 132 providing specification information relating to the type of parts needed for replenishment, the cost, and the quantity and location of each part within the manufacturing kit 132 .
- FIG. 2 is a schematic representation of shelving system 12 electronics embedded within vertical and horizontal channels 40 , 42 .
- Each rack 36 a , 36 b . . . 36 n includes a rack control unit 20 a , 20 b . . . 20 n providing power, control, and communication through power and data cables 48 .
- Each rack control unit 20 a , 20 b . . . 20 n has a rack processor 47 a , 47 b . . . 47 n connected to a communications bus 49 that provides a communications link to network node proxy 50 and to other rack processors 47 a , 47 b . . . 47 n .
- shelf electronics 60 a , 60 b . . . 60 n such as a shelf address decoders 62 a , 62 b . . . 62 n , data latches 63 a , 63 b . . . 63 n , and power drivers 64 a , 64 b . . . 64 n .
- Shelf electronics 60 a , 60 b . . . 60 n are connected to rack control units 20 a , 20 b . . . 20 n through data cables 48 embedded within vertical and horizontal channels 40 , 42 .
- a method according to the invention begins at operations 200 and 202 , respectively, by placing a manufacturing kit 132 onto mobile pick-station 100 and scanning the kit barcode 130 using the mobile pick station scanner 106 .
- pick station processor 102 Upon scanning at operation 204 , pick station processor 102 initiates a database query to data server 120 for kit specification data via network interface 110 .
- the query provides mobile pick station 100 with kit specification data identifying the parts needed for replenishment and their locations.
- the retrieved data is used to generate a map 140 of the selected manufacturing kit 132 onto touchscreen display 108 , which is located on mobile pick station 100 .
- the map 140 shown in FIG. 4 , visually represents an overlay of the manufacturing kit 132 and shows the respective specification data including the kit compartments 150 .
- a color-coded graphic 144 located inside each of the compartments 150 , is coded to match the color of illuminated pick-light 30 , 32 , 34 . Inside the color-coded graphic 144 there is information 148 representing the type of part needed for that particular compartment 150 , and the quantity and storage bin location 26 of the particular part.
- the specification data retrieved by the query of operation 206 is used by the pick station processor 102 at operation 210 to command the network node proxy 50 to illuminate one of the three pick-lights 30 , 32 , 34 located below the pick-face 28 associated with each bin 26 , for each part in the selected kit 132 .
- the map 140 and illuminated pick-lights 30 , 32 , 34 guide the user to the location of the parts needed to replenish the manufacturing the kit 132 .
- the system 10 is capable of replenishing more than one manufacturing kit 132 , simultaneously.
- the currently displayed map 140 is shown in a list of active kits 141 .
- the user may change the displayed kit by selecting the desired kit from the listing 141 .
- the system 10 can also perform tasks such as restocking the storage bins and servicing emergent requirements. For example, a red pick-face light may indicate a part is needed for kit replenishment, while the same set of pick-face lights 30 , 32 , 34 has a yellow light illuminated representing a servicing emergent requirement. Further, a green light may be lit to represent parts needing to be restocked. This multi-tasking allows more than one user to use the system at the same time. An emergent requirement process is discussed below.
- a user replenishes a kit 132 by moving mobile pick station 100 to each storage bin 26 location having an illuminated pick-face light 30 , 32 , 34 .
- the user scans the pick-face barcode 29 , using the scanner 106 , to validate the pick.
- the system 10 determines whether the correct pick-face 28 was scanned.
- at least one illuminated pick-face light 30 , 32 , 34 and color-coded graphic 144 begin to flash confirming the correct selection.
- the flashing color-coded graphic 144 is intended to guide the user to place the selected part into the proper kit compartment 150 .
- a photo of the desired part, along with other specification data, is displayed on the map 140 as shown in FIG. 4 .
- an audible alarm sounds indicating to the user that the wrong pick-face 28 was scanned and the correct part needs to be located.
- the user takes corrective action to resolve the error.
- the user selects the flashing graphic 144 on the touch screen 108 , at operation 228 , to reconfirm that the part has been placed in the correct compartment 150 .
- the flashing graphic 144 By selecting the flashing graphic 144 at operation 230 , the correct placement of the part is confirmed and one or more of the illuminated pick-face lights 30 , 32 , 34 and the flashing graphic are extinguished.
- the user moves to the next illuminated pick-face light 30 , 32 , 34 to make another selection until the kit is completely replenished.
- FIG. 5 illustrates a method according to the present invention for servicing emergent requirements.
- An emergent requirement is an unanticipated need received from the factory floor for a pick part that was either not found in the kit being on the part was found defective. In either case, the part is needed on the factory floor quickly.
- a user typically a floor mechanic from the work site, using a web interface, orders the parts needed to complete a job.
- the web server 121 queries a database for information related to the selected parts.
- the selected parts are stored into an emergent order table at operation 304 , until the user completes the order at operation 306 .
- the system 10 sends the request to the pick area and notifies the user by illuminating one or more of the corresponding pick-lights 30 , 32 , 34 , by flashing a beacon light and by sounding an audible alarm.
- the system 10 sends a message at operation 310 , generally via an alphanumeric pager, to the pick area user communicating the emergent requirement order. Labels are printed at operation 312 at the pick station 100 for labeling special order part bags.
- the pick area user fills the emergent order in the same manner as the kit replenishment process explained above. Preferably, an emergent order can be filled and delivered to the user within three minutes of requesting the order.
Abstract
Description
Claims (17)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US11/347,684 US7195156B2 (en) | 2002-10-29 | 2006-02-03 | Pick-to-light system for replenishing manufacturing kits |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US42196802P | 2002-10-29 | 2002-10-29 | |
US10/347,754 US7077318B2 (en) | 2002-10-29 | 2003-01-21 | Pick-to-light system for replenishing manufacturing kits |
US11/347,684 US7195156B2 (en) | 2002-10-29 | 2006-02-03 | Pick-to-light system for replenishing manufacturing kits |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/347,754 Continuation US7077318B2 (en) | 2002-10-29 | 2003-01-21 | Pick-to-light system for replenishing manufacturing kits |
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US20060124743A1 US20060124743A1 (en) | 2006-06-15 |
US7195156B2 true US7195156B2 (en) | 2007-03-27 |
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US10/347,754 Expired - Fee Related US7077318B2 (en) | 2002-10-29 | 2003-01-21 | Pick-to-light system for replenishing manufacturing kits |
US11/347,684 Expired - Fee Related US7195156B2 (en) | 2002-10-29 | 2006-02-03 | Pick-to-light system for replenishing manufacturing kits |
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US10/347,754 Expired - Fee Related US7077318B2 (en) | 2002-10-29 | 2003-01-21 | Pick-to-light system for replenishing manufacturing kits |
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Cited By (6)
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US20090210247A1 (en) * | 2008-02-20 | 2009-08-20 | The Chudy Group, Llc | System and Apparatus for Item Management |
US20100030667A1 (en) * | 2008-08-04 | 2010-02-04 | The Chudy Group, Llc | Adaptive Pharmaceutical Product Management Methods and System |
US20100030371A1 (en) * | 2008-07-30 | 2010-02-04 | The Chudy Group, Llc | Pharmacy Will-Call and Prescription Order Article Management System |
US9679447B2 (en) | 2014-01-28 | 2017-06-13 | The Raymond Corporation | Material handling vehicle with product placement indication |
US10358247B2 (en) | 2017-10-27 | 2019-07-23 | Chudy Group, LLC | Compartmentalized container loading and management system |
US11264124B2 (en) | 2008-02-20 | 2022-03-01 | Chudy Group, LLC | System and apparatus for item management |
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US20070142961A1 (en) * | 2005-12-21 | 2007-06-21 | Caterpillar Inc. | System and method for providing visual aids |
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US7937176B2 (en) * | 2008-11-14 | 2011-05-03 | International Business Machines Corporation | Hybrid part installation process combining mass part installation techniques with discrete part number assembly activities |
US20100319176A1 (en) * | 2009-06-23 | 2010-12-23 | E. I. Du Pont De Nemours And Company | Smart system for vehicle cosmetic repair |
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US20140172490A1 (en) * | 2012-12-17 | 2014-06-19 | David M. Snyder | System, method, and apparatus for managing and performing geographically distributed cell-based manufacturing and/or assembly |
US20140214631A1 (en) * | 2013-01-31 | 2014-07-31 | Intermec Technologies Corporation | Inventory assistance device and method |
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US10764960B2 (en) | 2018-11-01 | 2020-09-01 | Delta Electronics Int'l (Singapore) Pte Ltd | Wireless sensor network and parameter optimization method thereof, and warehouse system |
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US20220318727A1 (en) * | 2019-06-03 | 2022-10-06 | Vdms Limited (Ireland) | Live inventory management system and methods thereof |
US10897979B1 (en) | 2019-09-12 | 2021-01-26 | SureTint Technologies, LLC | System and method for hair dye color conversion |
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Also Published As
Publication number | Publication date |
---|---|
US7077318B2 (en) | 2006-07-18 |
US20060124743A1 (en) | 2006-06-15 |
US20040083144A1 (en) | 2004-04-29 |
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